Floor joist and assembly



July 19, 1960 Filed March 2, 1954 H. WEBB 2,945,328

FLOOR JOIST AND ASSEMBLY "Z5 Sheets-Sheet 1 Fig-.2.

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o 27La6 INVENTOR LEONARD HUGH WEBB ATTORNEY July 19, 1960 L. H. WEBB FLOOR JOIST AND ASSEMBLY 3 Sheets-Sheet 2 Filed March 2, 1954 2 BET INVENT OR LEONARD HUGH WEBB ATTORNEY July 19, 1960 L, H, WEBB 2,945,328

FLOOR JOIST AND ASSEMBLY Filed March 2, 1954 3 Sheets-Sheet 3 INVENTOR LEONAR D HUGH WEBB ATTORNEY FLOOR JOIST AND ASSEMBLY Leonard Hugh Webb, Girard, Ohio, assignor to Websteel Framing System, Inc., Youngstown, Ohio, a corporation of Ohio Filed Mar. 2, 1954, Ser. No. 413,637 6 Claims. (Cl. 50-283) and to improved methods for assembling such constructions.

nited rates Patent 9 The primary object of the invention is the provision of improved structural elements, particularly floor, joists, which are efiicient in utilization of basic material and which may be readily produced in an economical manner by high speed machinery whereby efficient and lightweight fioor structures and assemblies may be furnished at substantially lower cost than is possible by the use of presently known structural sections and methods. Basically, the system of my invention revolves about a novel design of a metal joist which is preferably manufactured in a continuous and economical manner from coiled metal strip by the use of a continuous cold roll forming machine. In the heavier gauges, such as 16 gauge, for example,and without exceptional analysis or surface finish, coiled metal strip is economical structural material and while heretofore many proposals have been made to uti lize sections rolled from such material in a continuous manner, particularly for floor assemblies, the result has not generally been acceptable unless field welding or other costly field assembly methods were used in the utilization of the rolled sheet metal sections. It is accordingly a further object of the invention to increase the strength and rigidity of floor panels and structures using rolled sheet metal joists while yet enabling the floor structures to be assembled in the field in a rigid and expeditious manner without the use of welding or other costly techniques.

A further object of the invention is the provision in a floor assembly using rolled sheet metal joists of an improved arrangement whereby the upper flanges of the joists are maintained rigidly in proper transverse spacing and are prevented from creeping in a longitudinal direction with respect to the flooring material supported on the joist. In this manner more eificient box-like sections are obtained and the resulting structure is quiet, rigid and strongv even though assembled of relatively lightweight materials.

Yetv another object of the invention is the provision of low-cost lightweight floor structures for buildings which may be expeditiously pre-assembled into panels of handlable size either at the manufacturing site or at the building site whereby definite economies may be efiected in the construction of buildings.

It is the purpose of this invention to provide low cost "lightweight preformed joist and other sections which may I be rigidly pre-assernbled either at the manufacturing plant or at the building site, as desired, into more or less standardized panels to facilitate erection, which are highly versatile in their application to various types of floor structures, and which when incorporated in the complete structures contribute certain structural advantages. Thus,

if poured concrete floors are to be used, a portion ofthe tion;

sections of this invention are embedded in the mass of the concrete thereby not only effectively reinforcing the same but also insuring that the sections themselves will be most rigidly maintained in proper spacing and re strained against creeping as above outlined. In wooden floor. construction the structural sections of the invention provide adequate spaced and extended bearing surfaces to support the conventional plywood sub-flooring used without excessive unit loading and, again, the final assembly is such that the supporting structural sections are so rigidly secured to the broad expanses of the plywood sub-flooring that an extremely quiet and rigid overall assembly is effected.

Another object of the invention resides in the provision of a floor structure assembly of the general type described above which is provided with novel and highly advantageous arrangements for assembling and supporting ceiling material from the lower side of the floor assembly. To this end the invention contemplates the provision of highly flexible and easily and quickly assembledmeans for supporting standard-sized slabs or panels ofceiling material, the invention further contemplating the incorporation into the ceiling structure of ceiling materials of substantially all types including architectural Sheet rock, plywood, acoustical tile and ner of incorporating the assembly into a complete building structure;

Figure 4 is a section view through an assembled floor section constituting a second embodiment of my mven;

Figures 5 and 6 are fragmentary side and end section views respectively of a novel structural beam or joist constituting an important feature of the invention; v

Figures 7 and'8 are enlarged fragmentary side and top views respectively of a bracing and supporting member incorporated into the assembly of Figure 4;

Figure 9 is a plan view of a bracing strut which is incorporated into the assemblies of Figure ,1 and Figure 4; t

Figures 10 and 11 are fragmentary section views of assemblies of the type shown in Figure 4, illustrating alternative arrangements for incorporating ceiling structures into completed floor assemblies;

Figure 12 is an. end elevation of an assembly jig employed in the construction of floor assemblies of the type shown in Figure 4;

Figure 13 is a fragmentary plan view of a ceiling structure incorporating certain important teachings of my invention; and

' Figure 14 is an enlarged fragmentary section view The joists 10 are formed of sheet metal and have flat bottom portions 12 and upwardly extending outwardly diverging side walls 13 and 14, the extreme upper end portions 15 and 16 of the side walls being bent outward- 3 ly to form outwardly extending flanges defining a common supporting surface. The joists are formed of sixteen gauge metal, for example, or of lighter or heavier stock depending on load and. span factors, suitable continuous cold rolling processes being employed to elfect the described U-shaped configuration.

In accordance with the teachings of the invention the upper flanges 1S and 1-6 of each joist are provided with a plurality of apertures for the reception of suitable fastening devices such as barbed nails 17; and in this manner the panel 11 is rigidly secured to a plurality of joists in the manner desired. I prefer thatthe fasteners 17 be spaced approximately four inches apart along theentire length of and at each side of each joist.

It is one of the primary objects of the invention to provide a pre-assembled flooring unitfor bodily incorporation into a building structure, and to thisend I prefer to utilize standard plywood panels of four foot width,

assembled end-to-end in any desired length up to, for example, 32 feet, the plurality of thus assembled plywood panels comprising the sub-flooring panel designated by the numeral 11.

In the preferred construction the right hand joist (as viewed in Figure 1) is centered approximately thirteen and three-eighths inches from the right hand edge of the panel and the remaining joists are spaced on sixteen inch centers. The arrangement is such that the left hand joist 10 is located adjacent the left hand edge of the panel 11. And in accordance with the preferred teachings of the invention the joist 10" is provided along its left hand edge with an enlarged flange which extends outwardly of the left hand edge of the panel 11 and is provided with parallel rows of apertures, not specifically shown, for securing the left hand edge of panel 11 and the right hand edge of an adjacent panel 11', shown in broken lines in Figure 1. In this manner a complete floor assembly may be readily constructed from a plurality of separate assembled units of the type shown in Figure 1.

Where it is desirable to provide a ceiling surface along the lower sides of the joists 10 and 10' I provide a plurality of bracing struts 18 (see Figure 9) which comprise angle sections having bayonet-like end portions 19 which are adapted to be received in suitable apertures 19' spaced regularly along the joists, atsixteen inch centers for example. As shown in Figure 9 the bracing struts are provided along their lower sides with a plurality of apertures 20 for the reception of suitable fastening devices not shown, for supporting lath work, also not shown. The arrangement is similar to that shown in Figure 10, wherein fastening devices 21 support. lath 22, and plaster 23.

Preparatory to installing the pre-assembled panel units 10-11 into a building structure a, sill 2.4 is secured to the foundation blocks 25, and in turn a. header 26. is secured to the outside edge of the sill. 24, the header being substantially the same height. as the main joists 10 and 10. formed vertical outwardly extending flanges 27 which are provided with a plurality of apertures, and bolts 28 or other fastening devices are received in the apertures; for securing the joists to the header 26.

When a plurality of panel units or sub-assemblies are thus assembled and incorporated into the building structure, suitable finish flooring- 29 may be added and a ceiling is formed, if desired, to. cover the lower sides of: the

joists.

Referring now to Figures 4-11 there is shown a second embodiment of my invention which. is applicable in installations wherein concrete rather than wood flooring is, desired. In this embodiment there isprovided a plurality of flooring units. or sub-assemblies comprising a pluralitypreferably four-elong;ated roll-formed joists 30 of u-shaped cross, section, substantially similar to .4, joists 10 heretofore described. The joists 30 are provided with outwardly extending flanges comprising integral upper portions of outwardly diverging side walls 32. However, in the embodiment of Figure 4 the flanges 31 are not apertured, as in the embodiment of Figure 1.

In accordance with the teachings of the invention the joists 30 are provided along their side wall portions, below the flanges 31', with L-shaped apertures 33 to re ceive and conform substantially to transversely disposed angle sections 34. The apertures 33 are spaced on, for example, sixteen inch "centers and arranged in aligned pairs so that in the assembled structure the angle sections 34 are received in each of the four joist members 3t) comprising a complete sub-assembly.

As shown in Figures 7 and 8, the angle sections 34 are provided along one edge with longitudinally spaced serrations forrning tabs 35. Preferably the tabs 35 are so spaced that inthe complete sub-assembly there are three tabs positioned between each adjacent pair of joists 30, and at least one tab positioned outside each of the outermost joists.

When the tabs 35 are initially formed they remain substantially flush with the principal surface of the angle member 34 so that the latter may be readily inserted longitudinally into thealigned L-shaped apertures of a plurality of side-by side joists 30 during construction of the sub-assembly. .Once the angle members 34 are properly positioned the tabs 35 are bent upwardly, as at 35 in Figure 4.

At this point mesh or lath material 36 is laid over the tops of the angle members 34, the mesh 36 being in the form of longitudinal strips and preferably having longitudinally extending strengthening ribs 37 arranged to lie adjacent the upwardly turned tabs 35. As shown in Figure 4, the strips of mesh 36 extend substantially from one joist 30 to another so that the entire open space between any' pair of joists is covered by mesh. The mesh is. then secured in the desired position by bending the tabs 35 over the ribs 37; and preferably the angle sec -tions 34 are formed of sixteen gauge metal so that this ing contact with the side walls of the joist. The upturned edges also add strength to the strips 38 as will be readily understood.

In assembling, a complete floor structure a plurality of sub-assemblies of the type shown in Figure 4 maybe required; and to this end I provide a notch 39 in one end of each angle member 34 and a tab 40 at the other end. Thus, the angle sections 34' of a second sub-assembly may be interfitted with the angle sections 34 of a firstsub-assembly, and the complete assembly locked together by engaging each of the tabs 40 of sections 34 with the notches of sections 34.

Of course, in the embodiment of Figure 4, there is provided suitable means, not shown, for supporting the ends of the joists 30, this being done in a manner similar to thatshown in Figures 2 and 3, with vertical flanges 41 of the joists 30 being utilized to firmly lock. the joists 30, in position in the overallv building. structure.

After a complete floor skeleton has been assembled in. a building structure. a layer. 42. of concrete is poured over the mesh 36 and strips 38, and it will be observed in Figure 4 that the concrete completely embeds the outwardly extending flanges 31 of. the joists 30 so that an interlocking structure of. exceptional. strength and plied in a conventional manner.

durability is obtained. Where desired, of course, additional reinforcing mesh, not shown, may be embedded in the concrete in accordance with well known concepts of concrete construction work.

It will be observed in Figure 4 that in the completed floor structure the lower portions of the joists form enclosed tube-like passages which may be utilized for the housing of electrical cables 43, plumbing, not shown, or other components. Suitable access means 44 and conduit 45 may be embedded in the concrete for the final distribution of power to the exact points desired.

Figures 4, l and 11 illustrate alternate means for supporting ceiling structures from the floor assemblies. In Figure 4 bracing struts 18 are employed and the arrangement is substantially the same as that described with respect to the apparatus of Figure 1. In Figure the joists 30 are provided along their bottom walls with a plurality of longitudinally spaced apertures 46 for the reception of lath clips 21 of conventional design. The clips 21 engage and support suitable lath 22 which in turn supports a layer 23 of plaster, for example, ap-

In Figure 11 the lath 22 and plaster 23 are suuspended in spaced relation to the lower surface of the joists 30 by means of supporting wires 47, the wires 47 being received and secured in suitable apertures 48 provided in the angle sections 34. Preferably the apertures 48 are located adjacent the joists to take full advantage of the support provided by the side wall of the joist.

In Figures 13 and 14 there is illustrated a novel ceiling structure constituting an important feature of my invention. provided along their bottom walls with longitudinally extending rows of apertures 46 spaced on four inch centers, for example. Extending transversely of the joists 30 are bracing struts 18 which are spaced on sixteen inch centers, as are the joists 30. The arrangement is such that a grid-like structure is formed over the entire lower surface of the floor assembly, with the elements 18 and 30 of the grid defining squares measuring sixteen inches on a side. The struts 18 are of course provided with rows of apertures 20 as heretofore described.

In accordance with the teachings of the invention I provide a plurality of roll-formed splines 56 and 56 which are generally of inverted T-shape configuration, having continuous outwardly extending flanges 57 along their lower edges and having beaded portions 58 along their upper edges in which are embedded a plurality of upwardly extending spring clips 59. The clips 59 are spaced on four inch centers for registry with the apertures 20 or 46, in the struts 18 or joists 3t) respectively. The arrangement is such that the splines 56 and 56' may be rapidly assembled into the ceiling structure by merely aligning the clips and apertures and forcing the splines upwardly to engage the clips.

In the preferred arrangement the transversely disposed splines 56' are fifteen and one quarter inches in length while the longitudinally disposed splines 56 are threequarters of an inch in width and sixteen inches in length. Thus, the longitudinal splines 56 may be assembled endto-end to form a continuous support while the trans- I verse splines abut at each end against the side edges of the longitudinal splines, substantially as shown in Figure 13.

The complete ceiling structure of course includes panels 60 of suitable material, such as Sheetrock, accoustical tile, plywood, etc., which is commercially furnished in standard squares of the desired size. The panels 60 are readily assembled into the complete structure by first assembling one or more splines 56 or 56' and supporting the appropriate edge or edges of the panel on the flanges 57, substantially as shown in Figure 14. After the panel 60 is properly positioned the unsupported side edges are secured by assembling splines 56 or 56' along the open sides. The entire assembly procedure requires As heretofore described, the joists 3,0 are i against bending along a longitudinal axis.

To facilitate assembly of the apparatus of Figure 4 -I provide a novel jig, shown in Figure 12, which comprises a plurality of aligned supports 50, each having a transverse supporting bar 51 with a plurality of spaced joist receiving notches or grooves 52 therein for the reception of the bottom portions of a plurality of joists 30. Across the top of the supporting bar 51 is a guiding and supporting member 53 which, in accordance with the teachings of the invention supports one or more angle sections 34 at the level of the L-shaped apertures 33 when joists 30 are properly received in the troughlike grooves 52.

Thus, in constructing a floor skeleton sub-assembly the joists 30 are first positioned in the grooves 52, in transverse alignment, and the angle sections 34 are threaded in from the side, being guided and supported by the member 53. When all the sections 34 are properly in position the mesh 36 and strips 38 may be assembled, if desired.

I have found that two men, utilizing the apparatus of Figure 12, can easily assemble fifteen skeleton sub-assemblies of the type shown in Figure 4 in an hours time.

It should thus be apparent that I have accomplished the objects initially set forth. The invention provides substantially improved floor or floor skeleton assemblies, in addition to improved components for utilization therein and improved assembly procedures and apparatus.

The improved joistmember of my invention is easily and inexpensively formed by continuous metal forming processes, is lightweight and easily handled, and can be 'incorporated into a variety of floor structure designs,

only a few of which are illustrated herein. The outwardly extending continuous flange portions, forming 'the top of the generally U-shaped joist are utilized both to support and to secure wooden flooring, while in the construction of concrete flooring the flanges are embedded in the body of the concrete, providing an integrated structure of unusual strength and durability.

One of the highly advantageous features of my invention resides in the use of the plurality of transversely extending angle sections which interconnect the joists 30 prior to pouring of the concrete, and which also serve to support and secure the matting or lathing which acts as a base for the concrete layer. The angle sections are f serrated prior to assembly so that when the main components are in proper position fastening tabs may be easily and quickly formed for securing the mat or mesh 36 in position.

The above arrangement has further important advan tages in connection with the assembly jig provided therefor by the invention. The assembly jig is of a highly simplified nature which can be readily transported to the job site so that the actual construction of the preassembled floor skeletons may be advantageously effected at the job site. The assembly procedures and the tools required are of such a simplified nature that in many instances it will be more economical to ship the individual components, i.e., the joists and serrated angle members, direct to the site of constructionrather than to complete the subassemblies at a factory or warehouse site. And this is particularly true in the construction of multistory structures since the raising of individual components to the upper floors is often much more economically accomplished than the raising of the entire relatively bulky assembly.

In each of the disclosed sub-assemblies, convenient means are provided for making multiple assemblies so that a practically unlimited variety of styles and shapes of flooring may be. constructed :from the :basic. zsub assemblies. In all icasesrthe'bulkofathe 'assemblymaybe carz-riedzrmt at neutralized assembly or manufacturing "plants utilizing standardized: procedures and efiicient power :flexibility in :the type of ceiling material used; and varieties. of color designsv and patterns may be readily car- :ried out by :theaappropriate assembly of the individual :;panels ofrceiling material in" desired positions.

over, the assembly may-be carried out quickly and efficiently-and -for 'thetmost part without tools or special skills of anylkind.

- Another important advantage of the invention resides in the use in the complete floor assembly of generally U-shaped joists having outwardly diverging side Walls. The-joists of thistdesign are handled-while being of'adequate strength; and perhaps of more-importance, ,a plurality'ofjoists may be shipped in nested-arrangement, requiring an absolute minimum of shipping space. The other. components of the complete structure are, ofcourse, of such shape as to also occupy a minimum of shipping space.

. It.should .be understood, however, that. the embodiments herein..disclosedand specifically described are intended to. be representativee only, and .reference should :be had to .thefollowingappended claims inv determining .the full scope ofthe invention.

I claim: 1. Areinforcedconcrete building. floor structure. comprising spacedparallel .formed sheet metaljoists of gen- 'erally -Ushape cross section defining a bottom wall. and having upwardly and outwardly divergentside walls each capped by a continuous. outwardlydirectedflange, said side wallsv having transversely aligned -L-shaped apertures spaceddownwardly from said flanges and up Wardly fromsaid bottom wall, angle sections threaded through-said apertures. and-said joists and eachv being of a length. to .span a multiplicity of. said .joists,..metal. lath I clipped to .said angle sections and lyingbelow the level of: said..flanges,.sheet. metal. covers positioned in said joists and .also lying .on. said -angle sections, .and poured concrete. supportedionusaid lath.and said covers in con- .tinuousslab form and. wholly encompassing .said flanges. Y 2...A reinforced building structure. comprising longitudinally..extending. .spacedparallel formed. sheet metal .joists. otgenerally U-shaped cross section each defining a bottom wall and having upwardly and outwardly divergentside walls each having a continuous outwardly directed horizontalflange adjacent the top edge thereof and eXtendingiL-the entire length thereof, said side walls having transversely aligned apertures spaceddownwardly lightweight .and easily More- 1 s from said' flangesrsandzupwardly fromrsaid bottomzwalls at longitudinally spacedIpoints therealon'gg zlun'gitudinally spaced: continuous "structural members threaded: through said apertures and said joists andieach of:zsaid"structural .members being of :a length to spana multiplicity! of:said joists, said'joistsi and said structural members. defining a #grid-like-panelassembly, covering means having portions supported by said structural'members and :engaging'the top surfaces of said'structural members and thebottom surfaces'of said -flanges,':and said flangesebeing surrounded by and substantially encompassed bysaid covering means to providean interlock between saidjoists and said covering means.

3. Apparatus according to claim 2 further characterized in that said covering means comprisesmetal lath attached to said structural members and lying: below the level of'said flanges and'pouredconcrete supported'on said metal lath in continuous slab formrand surrounding said flanges to provide saidinterlock. 4. Apparatus according to claim 2 further characterized in. that each of said structural membersahas a horizontal top surface, and :said top surfaces of said structural' members being serrated to define a means for at- .taching said covering means to said structural members.

5. Apparatus according to clairn 2 further characterized inthat said side wallsiof said joists have apertures .therein at longitudinally spaced pointsvadjacentthe bottom. walls of said joists and below said structural members, and bracing struts extending transversely. between .Jadjacent ones of said joists having thewendsthereof received in said last mentionedapertures.

6. Apparatus according to claim 2 further characterized in that said bottom walls of said joists are apertured at longitudinally spaced points to receive clips for the support of ceiling material.

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